EP1917866B1 - Method for manufacturing in particular frozen mashed or pureed foods in portions - Google Patents

Abstract

The procedure for the production of deep-frozen, portioned pulp food or mash food, which is designated for the consumption in the thermal condition, comprises heating a carrier raw material in a water bath by stream or with hot air at a core temperature (T1) of 75[deg] C, suddenly cooling the raw material at a lower temperature (T2) of 5[deg] C, mechanically mincing the raw material by a micro-cutter, mixing the minced raw material with protein and transferring the pulp- or mash mixture in a dimensionally stable pulp- or mash food through heating at a core temperature (T3) of 70[deg] C. The procedure for the production of deep-frozen, portioned pulp food or mash food, which is designated for the consumption in the thermal condition, comprises heating a carrier raw material in a water bath by stream or with hot air at a core temperature (T1) of 75[deg] C, suddenly cooling the raw material at a lower temperature (T2) of 5[deg] C, mechanically mincing the raw material by a micro-cutter, mixing the minced raw material with protein, transferring the pulp- or mash mixture in a dimensionally stable pulp- or mash food through heating at a core temperature (T3) of 70[deg] C and suddenly cooling the dimensionally stable pulp- or mash food. The raw material for example vegetables, meat, fish, cereals or pasta is mixed with the other ingredients and is cooled, portioned and then cooked in further sequence. The heated and the cooled raw material is added before and/or when admitting the liquid such as water, base, cream, milk and/or oil. The ratio of the raw material and the liquid is 50:50. The average sliced product of the cooled and minced raw material is 0.3 mm. The minced raw material mixes with protein with or without extra liquid and is mixed to a homogeneous pulp- or mash mixture. The mixture containing the minced raw material and protein are admixed with further ingredients that consist of binding agent such as modified starch, gelling agent such as cattle gelatin with a bloom grade of 180-240, spices and/or saturation supplement such as cream cheese, powder, semolina, rice, rice flakes and/or curd. The admixing of the protein and the further ingredients takes place in an individual operation. A mixture of powdered chicken protein and lactalbumin in the ratio of 80:20 is used as protein. The pulp- or mash mixture is filled in a temperature-resistant silicon mold before the heating process. The heating of the pulp- or mash mixture filled in the silicon mold and the transfer of the mixture in the stable pulp- or mash food takes place by hot air, in which the humidity is injected. The sudden cooling of the pulp- or mash food takes place between 5-20 min after the heating process. The heating time (60%) during the transferring of the mixture is larger than the heating time (70%) during the heating of the raw material. An independent claim is included for a deep-frozen, portioned pulp food or mash food.

Description

The invention relates to a method for producing, in particular, frozen, portioned porridge or puffed egg crust, which is intended for consumption in the heated state, in which at least one heated and mechanically comminuted, especially mashed and / or pasted carrier raw material, for example vegetables, meat, fish, Cereals or pasta, is mixed with other ingredients and subsequently this mixture is cooled and portioned.

The production of frozen, portioned Püreekost is known, for example from US 6,676,986 ; JP 55 118 373 ; JP 59 166 063 ; JP 11 075 769 ; EP-A 0 966 887 , As a rule, the raw materials such as fruits, vegetables, meat and fish are cooked and crushed, or vice versa, and then finely passed before the raw materials treated in this way are deep-frozen in molds.

Frozen and portioned Püreekost offers the consumer decisive time and handling advantages, since preliminary work such as washing, cleaning, cooking, shredding and reworking such as the time-consuming cleaning of blenders is completely eliminated. The frozen portions only have to be thawed, individually seasoned and prepared.

A disadvantage of the known Püreekostformen has been found, however, that they lose their shape after thawing during the heating process and liquefy, so that the consumer depending on the raw materials used only finds different colored pulp on his plate, the distinction in main course and side dish no longer allow.

The invention has therefore set itself the task of providing a novel process for the preparation of preferably frozen, portioned Püreekost with which the above-described disadvantages can be avoided, so that the Püreekost has a visually appealing appearance even after thawing and heating.

The invention solves this problem by a novel method with the steps a) to e) according to the characterizing part of claim 1.

By heating the liquid, porridge or puree components twice, they can be shaped into dimensionally stable portion sizes. In other words, when process according to the invention in step a), the structure of the carrier raw materials is dissolved and destroyed according to step b), before protein is added in step c), whereby a renewed dimensionally stable structure is formed on repeated heating of this mixture according to step d) due to the binding capacity of the protein, but still has the properties of porridge or puree, ie the form-stable Püreekost melts in the mouth, so to speak, and does not have to be chewed, whereby the Püreekost produced by the novel process is particularly suitable for consumers with dysphagia.

For a safe dissolution of this primary structure and from a bacteriological point of view, it has been found to be advantageous according to an embodiment of the invention, when the carrier raw material according to step a) is heated to a core temperature of about 75 ° C.

Conveniently, the carrier raw material is cooked, wherein the heating of the carrier raw material can be done in a water bath, by steam or with hot air. It has been found to be particularly favorable for the subsequent processing steps if the various carrier raw materials are gently cooked in the steam without steam at temperatures of about 80 to 90 ° C until they reach a core temperature of 75 ° C before the carrier raw material according to step b ) is cooled to a temperature below 25 ° C, preferably below 15 ° C.

The immediate cooling of the carrier raw materials should on the one hand ensure that the nutrient density of the individual carrier raw materials is not lost and on the other facilitate the comminution process of the carrier raw materials, it has proved to be advantageous if the carrier raw material cooled to a temperature of about 5 ° C, preferably is cooled by a refrigerator.

Depending on the desired end product, liquid may be added to the heated and cooled carrier raw material before and / or during comminution, water, base, cream, milk or oil or a mixture thereof being added as liquid according to a further embodiment of the invention.

According to one embodiment of the invention, it is provided that the ratio of carrier raw material to liquid is between 30:70 and 10:90, preferably about 20:80. In this case, one speaks of liquid raw materials. As carrier raw materials are particularly fish, pork, poultry, game or vegetables.

Another embodiment provides that the ratio of carrier raw material to liquid is between 70:30 and 40:60, preferably about 50:50. In this case one speaks of Breirohstoffen, whereby as carrier raw materials mainly meat, fish and pasta are suitable.

If the carrier raw material is comminuted without the addition of liquid, this is referred to as purging raw materials. This Püreekostform is mainly used in vegetables, since in vegetables, the water content of the carrier raw material is sufficiently high.

To ensure that the end product does not contain any troublesome lumps or contiguous fibers, a further embodiment of the invention provides that the average size of the chopped and comminuted carrier raw material is less than 1.5 mm, preferably less than 1 mm, and it has proved to be particularly favorable has, if the average Schnittgutgröße is less than 0.7 mm, preferably about 0.3 mm.

In principle, the shredding can be carried out with any suitable device. However, a preferred embodiment of the invention provides that the comminution of the carrier raw material by means of a microcutter. A suitable microcutter, for example, the Stephan MCHD90V microcutter.

By heating during cooking and the subsequent comminution, the protein contained in the carrier raw material is denatured, that is, the binding ability of the product in a shaping and heating is no longer present. Since the binding capacity of the protein in the production of the slurry or püaveostform is required, provides a further embodiment of the invention, that comminuted with or without addition of liquid carrier raw material is mixed with protein and mixed to form a homogeneous brei- or Püreeförmigen mixture. Furthermore, it is possible that further ingredients are added to the mixture containing the comminuted carrier raw material and protein, wherein the admixture of the protein and the further ingredients preferably takes place in one working step.

According to the invention, preferably proteinaceous chicken protein is used as the protein, whereby a particularly good binding capacity and a high biological value are achieved when the protein used is a mixture of preferably powdered egg white protein and lactalbumin.

In this case, a further embodiment of the invention provides that the ratio of chicken protein to lactalbumin is between 70:30 and 90:10, preferably about 80:20.

In addition to the good binding ability and the high biological value, the use of egg white will further ensure that the finished mash or puke greens are dimensionally stable, but retain the properties of mash or puree, meaning that thawed and heated product can be consumed by the consumer be crushed with the tongue or the palate and is therefore particularly suitable for consumers with dysphagia.

The further ingredients according to a further embodiment of the invention may comprise binders, gelling agents, spices or satiety supplements or a mixture thereof.

It has been found to be advantageous if modified starch is used as a binder, since modified starch has several advantages over physical or enzymatic starches. Thus, modified starch is cold swelling, heat stable, acid stable, shear stable and freeze and thaw stable. In addition, modified starch has better flowability during filling. With the aid of the starch, the consistency of the mixture containing the comminuted carrier raw material and the further ingredients is adjusted in order to obtain a better filling property of the mixture. In addition, the use of binder prevents segregation of the raw materials, which can happen quite well without the addition of binder and gelling agent due to the low ph value, which can vary between 4 and 6.5.

According to a further embodiment of the invention, it is provided that cattle gelatin having a bloom degree between 150 and 270, preferably between 180 and 240, is used as the gelling agent. Such gelatin prevents syneresis in the heating and cooling of the individual end products and promotes the formation of a collagen structure, which prevents deformation of the end product in the warm or cooled state, whereby a perfect workflow can be ensured for the end user.

For the preparation of wholesome meals, it may be useful if, according to a further embodiment of the invention, cream cheese, semolina, rice, rice flakes or curds or a mixture thereof is used as the saturation supplement.

As with shredding, all suitable equipment can be used for the mixing process. Experiments by the Applicant have shown, however, that a particularly favorable mixing result can be achieved with a tumble mixer. The mixing container is filled to about 2/3 of its volume with the respective mixture and for a preselected time, for example between 5 and 10, preferably between 8 and turned 10 minutes overhead. The inclined position of the mixing container, together with the mixing cross mounted on the underside of the lid, reinforces the mixing effect. In this way, the mixed product is spared and processed properly. A suitable tumbling mixer is, for example, the Fuchs Mixomat tumble mixer.

If the mixing process, in which the mix has a temperature of about 10 to 15 ° C, completed, there are essentially two options for further processing.

Thus, an embodiment of the invention provides that the brei or Püreeförmige mixture is filled prior to the heating process according to step d) in a temperature-resistant plastic intestine and the heating of filled in the plastic intestine brei or Püreeförmigen mixture and the transfer of the same into a dimensionally stable or Püreekost in a water bath or by steam. The filling of the heat-resistant plastic casing, whose diameter can vary between 3 and 15 cm, can be done for example by means of a vacuum filler.

According to a preferred embodiment of the invention, it is provided that the plastic casing containing the heated and dimensionally stable porridge or biscuit contains between 5 and 20 minutes, preferably between 10 and 15 minutes, at a temperature between 5 and 15 ° C., preferably at 10 ° C. cooled and then portioned it and the portions are frozen, preferably shock-cooled.

Another embodiment of the invention provides that the bre- or Püreeförmige mixture is filled before the heating process according to step d) in temperature-resistant molds, preferably silicone molds, and then the heating of the filled in the forms brei or Püreeförmigen mixture and the transfer same in one dimensionally stable mash or Püreekost by means of hot air, is sprayed into the moisture, before the frozen after the heating process dimensionally stable mash or Püreekost frozen forms, preferably shock-cooled, are.

Regardless of whether the cooked carrier raw materials are comminuted with or without liquid addition, whether other ingredients are added in addition to protein and whether the filling of the raw material takes place in an artificial gut or in silicone molds, an essential basic idea of the invention is in any case that the heating time t _{2 in} accordance with Step d) is shorter than the heating time t ₁ according to step a). A gentle second heating can be ensured if the heating time t _{2 is} more than 25% of the heating time t ₁ , wherein it has proven to be favorable if the heating time t _{2 is} between 50% and 80%, preferably between 60% and 70%. which is heating time t ₁ .

• 20 kg Rinderbrei (Rindfleisch und Rindsfond))
• 13 kg Sahne mit einem Fettgehalt von 10 bis 36 %, idealerweise von 20 bis 25 %
• 7 kg Frischkäse mit einer Trockenmasse von 45 %
• 0,4 kg Gulaschgewürz
• 0,03 modifizierte Stärke (kaltquellend) auf Basis von Mais, Reis, Kartoffel oder Getreide
• 0.1 kg Proteine in Form von 80 % Hühnereiweißpulver und 20 % Lactalbumin
• 1 kg Rindergelatine (240 Blom)

Hereinafter, an embodiment of a frozen portioned porridge and mash, which was prepared in particular by the method according to the invention and is characterized in that it has a dimensionally stable protein structure after thawing and heating, described:

• 20 kg of beef (beef and beef stock)
• 13 kg of cream with a fat content of 10 to 36%, ideally from 20 to 25%
• 7 kg cream cheese with a dry matter of 45%
• 0.4 kg goulash spice
• 0.03 modified starch (cold swelling) based on corn, rice, potato or cereals
• 0.1 kg proteins in the form of 80% egg white powder and 20% lactalbumin
• 1 kg of beef gelatine (240 blom)

In this embodiment, it is beef goulash, in which the proportion of the carrier raw material in the final product is about 80%. This percentage may vary between 50 and 90%, depending on the starting material and the end product desired.

To produce the final product, the beef is heated with 80 to 90 ° C hot steam or 120 ° C hot hot air to 75 ° C core temperature and then immediately cooled to 5 ° C, so that the nutrient density is not lost. The cooked beef meat is then crushed together with beef stock in a Stephan microcutter. These Crushed mash is then blended with the cream cheese, goulash spice, modified starch, protein and beef gelatin in a Fuchs Mixomat tumble mixer.

After mixing, the produced mixture is filled with a vacuum filler in a heat-resistant plastic casing and heated in a water bath to a core temperature of 75 ° C. These dimensionally stable intestinal rods, which can be between 5 and 14 cm in diameter, are subsequently briefly cooled, cut into slices of 1.5 to 4 cm, then deep-frozen or immediately deep-frozen and then sliced.

• 1. Herstellung der Flüssig-, Brei- oder Püreekostform (Fleisch dämpfen, mit Flüssigkeit versetzen und im Mikrocutter zerkleinern)
• 2. Sahne, Frischkäse, Topfen, Joghurt oder Mascarpone zugeben
• 3. Gelatine in der 15-fachen Wassermenge einweichen und erhitzen
• 4. die Trockenprodukte, beispielsweise Eiweiß, Stärke und/oder Gewürze gut mischen und
• 5. die ganzen Zutaten mit dem Mixomat mischen
• 6. den Darm im lauwarmen Wasser 15 Minuten einweichen und die Masse mit dem Vakuumfüller einfüllen
• 7. im Wasserbad, Dampf- oder Heißluftofen bei 80 bis 90°C erhitzen (Formgebung)
• 8. kurz, 10 bis 15 Minuten, bei ca. 10 °G kühlen
• 9. in Portionen schneiden und im Spiralfroster schockkühlen oder
• 9a zuerst schockkühlen und danach in Portionen schneiden.
• 10. in beispielsweise 1 bis 5 kg große Gebinde verpacken.

A very general recipe for producing dimensionally stable porridge or püreekost includes the steps

• 1. Preparation of the liquid, slurry or püaveost mold (steaming meat, adding liquid and chopping in the microcutter)
• 2. Add cream, cream cheese, curd cheese, yogurt or mascarpone
• 3. Soak gelatine in 15 times the amount of water and heat
• 4. mix the dry products, such as egg white, starch and / or spices well and
• 5. Mix the whole ingredients with the Mixomat
• 6. soak the intestine in lukewarm water for 15 minutes and fill in the mass with the vacuum filler
• 7. heat in a water bath, steam or hot air oven at 80 to 90 ° C (shaping)
• 8. short, 10 to 15 minutes, cool at about 10 ° G
• 9. cut into portions and cool in the spiral freezer or
• 9a Shock-cool first and then cut into portions.
• 10. Pack in, for example, 1 to 5 kg containers.

Further advantages and details are explained in more detail with reference to the drawing.

From the single figure, the novel temperature profile of the manufacturing process of the invention is clearly visible. During the heating according to step a) of the process according to the invention, the core temperature T _{1 of} the carrier raw material increases to 75 ° C. and rapidly drops to a temperature T ₂ of 5 ° C. as a result of the subsequent cooling. In further sequence, namely during steps b) and c), the temperature settles to a value of about 10 ° C, before it rises again in the heating according to step d) of the method according to the invention to a core temperature T ₃ of 75 ° C. to sink into the minus region upon cooling and freezing in step e).

The frozen, portioned porridge or Püreeformkost produced by the method according to the invention is, as already mentioned, especially for consumers with dysphagia and can be brought in the microwave by induction by steam or hot air ovens to a core temperature of 75 to 80 ° C and regenerated , In this regeneration, the products remain dimensionally stable and get their porridge or Püreekoststruktur. In the sensor test series performed by the Applicant, the structural specifications for consumers with swallowing complaints of products made by the novel process have always been achieved. In addition, home service providers have been conducting special series of induction plate tests, reaching temperatures in excess of 100 ° C, and surprisingly still remaining dimensionally stable. Further attempts by the Applicant have shown that the porridge or purée prepared in this way remain stable even when regenerated at low temperatures between 35 and 60 ° C and do not disintegrate.

It goes without saying that the invention is not limited to the embodiment described. In any case, one basic idea of the invention is to cook the carrier raw materials in a first step, then to comminute them and to mix them with protein and in turn to build up a protein structure via a second heating process.

Claims (28)

1. A process for the production of in particular deep-frozen, portioned mashed or pureed food which is intended for consumption in the heated condition, in which at least one heated and mechanically minced, in particular pureed and/or strained carrier raw material, for example vegetables, meat, fish, cereal or pasta is mixed with further ingredients and subsequently said mixture is cooled and portioned, characterised by the following steps:

   a) heating the carrier raw material to a core temperature T, of at least 60°C, preferably at least 70°C;

   b) cooling, preferably shock cooling, of the carrier raw material to a substantially lower temperature T₂ and mechanically mincing the carrier raw material;

   c) mixing the minced carrier raw material with protein and mixing to give a homogeneous mashed or pureed mixture, wherein chicken albumin - preferably in powder form - or a mixture of chicken albumin - preferably in powder form - and lactalbumin is used as the protein;

   d) converting the mashed or pureed mixture into a mashed or pureed food which is stable in respect of shape by heating to a core temperature T₃ of at least 60°C, preferably at least 70°C; and

   e) cooling, preferably shock cooling, of the mashed or pureed food which is stable in respect of shape.
2. A process according to claim 1 characterised in that the carrier raw material according to step a) is heated to a core temperature T₁ of about 75°C.
3. A process according to claim 1 or claim 2 characterised in that the carrier raw material is cooked.
4. A process according to one of claims 1 to 3 characterised in that the step of heating the carrier raw material is effected in a water bath, by means of steam or with hot air.
5. A process according to one of claims 1 to 4 characterised in that the carrier raw material in accordance with step b) is cooled to a temperature T₂ of below 25°C, preferably below 15°C.
6. A process according to claim 5 characterised in that the carrier raw material is cooled to a temperature T₂ of about 5°C.
7. A process according to one of claims 1 to 6 characterised in that liquid is added to the heated and cooled carrier raw material before and/or upon mincing.
8. A process according to claim 7 characterised in that water, meat juices, cream, milk or oil or a mixture thereof is added as the liquid.
9. A process according to claim 7 or claim 8 characterised in that the ratio of carrier raw material to liquid is between 30:70 and 10:90, preferably about 20:80.
10. A process according to claim 7 or claim 8 characterised in that the ratio of carrier raw material to liquid is between 70:30 and 40:60, preferably about 50:50.
11. A process according to one of claims 1 to 10 characterised in that the average cut material size of the cooled and minced carrier raw material is below 1.5 mm, preferably below 1 mm.
12. A process according to claim 11 characterised in that the average cut material size is below 0.7 mm, preferably about 0.3 mm.
13. A process according to one of claims 1 to 12 characterised in that mincing of the carrier raw material is effected by means of a microcutter.
14. A process according to one of claims 1 to 13 characterised in that further ingredients are added to the mixture containing the minced carrier material and protein, wherein the addition of the protein and the further ingredients is preferably effected in one working step.
15. A process according to claim 14 characterised in that the further ingredients include binding agent, gelling agent, spices or saturation supplements or a mixture thereof.
16. A process according to claim 15 characterised in that modified starch is used as the binding agent.
17. A process according to one of claims 15 and 16 characterised in that cattle gelatine with a Bloom degree of between 150 and 270, preferably between 180 and 240, is used as the gelling agent.
18. A process according to one of claims 15 to 17 characterised in that cream cheese, semolina, rice, rice flakes or quark or a mixture thereof is used as the saturation supplement.
19. A process according to one of claims 1 to 18 characterised in that - when using a mixture of preferably powder-form chicken albumin and lactalbumin as protein - the ratio of chicken albumin to lactalbumin is between 70:30 and 90:10, preferably at about 80:20.
20. A process according to one of claims 1 to 19 characterised in that the mashed or pureed mixture is filled into a temperature-resistant plastic case prior to the heating process in accordance with step d).
21. A process according to claim 20 characterised in that heating of the mashed or pureed mixture introduced into the plastic case and conversion thereof into a mashed or pureed food which is stable in respect of shape is effected in a water bath or by means of steam.
22. A process according to claim 20 or claim 21 characterised in that the plastic case containing the heated mashed or pureed food which is stable in respect of shape is cooled for between 5 and 20 minutes, preferably between 10 and 15 minutes, at a temperature between 5 and 15°C, preferably at 10°C, and is then portioned and the portions are deep-frozen, preferably shock-cooled.
23. A process according to one of claims 1 to 19 characterised in that the mashed or pureed mixture is filled into temperature-resistant moulds, preferably silicone moulds, prior to the heating process in accordance with step d).
24. A process according to claim 23 characterised in that heating of the mashed or pureed mixture filled into the moulds and conversion thereof into a mashed or pureed food which is stable in respect of shape is effected by means of hot air into which moisture is sprayed.
25. A process according to claim 23 or claim 24 characterised in that the moulds containing the mashed or pureed food which is stable in respect of shape after the heating process are deep-frozen, preferably shock-cooled.
26. A process according to one of claims 1 to 25 characterised in that the heating time t₂ in accordance with step d) is shorter than the heating time t, in accordance with step a).
27. A process according to claim 26 characterised in that the heating time t₂ is more than 25% of the heating time t₁.
28. A process according to claim 26 or claim 27 characterised in that the heating time t₂ is between 50% and 80%, preferably between 60% and 70%, of the heating time t₁.

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